Colloide's Journey into Lean
Looking back at the beginning of Colloide’s journey into lean, the first half of 2025 stands out as a period of transformative change. Between January and June, Colloide achieved a transformative milestone in our manufacturing processes, reducing production time from 6 weeks to 6 days and a remarkable 90% reduction in lead time. This success is the result of embracing lean manufacturing principles and practices, which have improved our efficiency and established a culture of continuous improvement company wide.
Colloide Pre-Lean Adoption
Before adopting lean principles, Colloide faced challenges despite having a full order book. Our average build and test cycle was significantly longer than desired, and meeting deadlines often relied on increasing headcount rather than tackling underlying inefficiencies. We operated within a traditional batch-and-queue manufacturing system, where the team could clearly see the limitations and bottlenecks in our processes.
Transformative Improvements using Lean
Colloide’s lean journey began with guidance from two external lean experts from Invest NI and ShopFloorLive, alongside a comprehensive workforce training programme and the establishment of a lean support group. The first area of focus in our lean journey was preparing for AMP8, and therefore collaboration between engineering and manufacturing teams was prioritised. Through these efforts, several key improvements have been implemented so far.
Production Lean Improvements
Kanban and Flow
The introduction of Kanban visual management enabled Colloide to adopt a pull-based production system. By producing only what was needed, when it is needed, we eliminate the waste caused by overproduction and create a smoother, more predictable workflow. This shift not only streamlines operations but also empowers the team, giving clear visibility of tasks and priorities and fostering a sense of ownership across the production process.
Design for Manufacturing
Engineering design changes were made to simplify processes, reduce setup times, and eliminate time-consuming measurements. By applying design thinking principles, Colloide not only made manufacturing more efficient and adaptable but also strengthened the link between the shop floor and office-based teams. Design and production became better aligned, with improved communication and collaboration ensuring that changes were practical, actionable, and supported seamless workflow.
Rethinking Assembly
Previously, 100% of wiring was completed inside chemical dosing kiosks. With lean adaptations, 95% of wiring is now pre-wired on benches using jigs and fixtures. This adjustment has significantly reduced assembly time.
Shop Floor Live System
The implementation of the Shop Floor Live system introduced real-time production visibility and clear daily routing guidance. The system enhances visual management at the point of work while improving workflow transparency.
Lean Morning Meetings
On 9 September 2025, Colloide held its first Lean Morning Meeting, led by Managing Director Paddy McGuinness. These meetings now take place every Tuesday morning for 15 minutes and have become a cornerstone of our lean culture. Presentations are now in full swing with presenters scheduled up to the end of the year. Staff provide updates from departments, recognise achievements, highlight customer satisfaction, showcase lean successes, and encourage engagement through interactive ice-breaker activities.
These meetings have strengthened communication, increased engagement, and fostered collaboration across teams.
Weekly Gemba Walks
Weekly Gemba Walks are another integral part of our lean journey. Originating from Japanese lean manufacturing principles, “Gemba” means “the real place”. These walks allow our staff to observe operational processes, see the impact of improvements that have been implemented, and share insights. By fostering hands-on learning and collaboration, Gemba Walks ensure that our lean principles remain embedded in daily operations and continue to deliver results.
Colloide’s Commitment to Lean Tours
When it comes to lean adoption and getting a team on board, Colloide maintain that, seeing is believing. Colloide are committed to giving every employee the opportunity to attend Lean tours, exploring workplaces that inspire innovation, efficiency, and collaboration. By experiencing first-hand how other organisations implement Lean principles, teams gain new perspectives, practical insights, and ideas that can be applied across Colloide’s own projects and processes. These tours foster engagement, spark creativity, and strengthen the company’s culture of continuous improvement. Looking ahead, Colloide hopes to launch its own Lean tours and join the wider local lean community in sharing its approach.
Digital Lean Tools & Lean in the Office
Colloide has transformed the way teams work together, gradually eradicating silos and fostering stronger cross-departmental communication. Lean is applied as rigorously in the office as it is on the shop floor: workflows are standardised, repetitive tasks are minimised, and processes are continuously reviewed to remove inefficiencies. Digital tools such as the Colloide Connect App, and systems for NCR’s, snags and stock processing, alongside other Lean-driven advancements, are streamlining reporting, improving transparency, and keeping everyone connected in real time. These innovations not only make project delivery faster and more efficient but also create a happier, more engaged team, ultimately enabling Colloide to deliver a higher-quality service and better outcomes for clients.
Lean is not just a strategy, it’s a mindset that promotes efficiency, collaboration, and excellence. At Colloide, we are proud to embrace this journey and look forward to sharing more information of our success and innovation in the months to come.
Lean at Colloide: Continually Improving
Want to see more stories, updates and progress from our lean journey? Head over to the Lean at Colloide Central page. Our space for all lean news, from continuous improvement projects to practical lean tips, it’s the hub that brings everything together. Make sure to check in regularly to see the progress we’re making and the ideas shaping the way we work.
